Rail and panel system for a pontoon boat

ABSTRACT

The invention relates to boundaries used on a watercraft. Specially, the invention relates to boundaries used on pontoon boats. The boundaries generally include a rail and panel system positioned around an outer periphery of the pontoon boat. The invention also relates to a method of forming and installing the boundaries on a watercraft.

FIELD OF THE INVENTION

The invention relates to boundaries used on a watercraft. Specially, the invention relates to boundaries used on pontoon boats.

BACKGROUND OF THE INVENTION

Watercraft such as pontoon boats generally include a plurality of rails supported by the deck of watercraft. The rails sometimes are positioned around the outer periphery of the deck to prevent passengers from falling overboard and to provide support of passengers. Typically, the rails cooperate with the deck or some other area of the watercraft to enclose a panel. The rail and panel may form a boundary around the outer periphery of the watercraft. In general, the panels are constructed of a metal such as aluminum.

SUMMARY OF THE INVENTION

One embodiment of the invention includes a watercraft including a frame, a rail supported by the frame, and a non-metallic panel supported by the rail.

Another embodiment of the invention includes a watercraft including a frame, a rail member supported by the frame, a panel member coupled to the rail, and means for coupling the panel member to the rail member.

Another embodiment of the invention includes a boundary for a watercraft, the boundary comprising a rail including a recessed portion and an extension, and a panel including first and second ends, the first end including an interlocking portion.

Another embodiment of the invention includes a method of manufacturing a watercraft, comprising the steps of providing a flotation platform, extruding a plurality of rails, defining a rail structure by attaching the plurality of rails to the flotation platform, providing a polymer based panel, and interlocking the polymer based panel to the rails to define a boundary wall.

Another embodiment of the invention includes a boundary for a watercraft, the boundary comprising a rail including a recessed portion and an extension, a panel configured to be attached to the rail, and cooperative interlocking members associated with the panel and the rail, the members configured to attach the panel to the rail.

Another embodiment of the invention includes a method of making a rail for a watercraft, and for use with a panel having tabs along an edge thereof, the method including the steps of providing a metallic material, and extruding the metallic material to produce a tube having a substantially square cross section including an extension and a recess, the recess adjacent to the extension.

Another embodiment of the invention includes a pontoon boat including a flotation platform defining a perimeter, a motor supported by the flotation platform, a plurality of rails supported by the flotation platform, the rails positioned around the perimeter, the rails including a substantially square tube having a recess and an extension positioned adjacent the recess, the extension including a first tab, and a plurality of polymer based panels having first and second ends and sides extending therebetween, each of the panels including a second tab on each side, the second tab configured to interlock with the first tab of the extension to secure the panels to the rail.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 2 is a elevated perspective view of a pontoon boat:

FIG. 1 is a cross-sectional view of one prior art embodiment of a rail used on a watercraft such as the pontoon boat shown in FIG. 1, the rail is shown in its preassembled configuration;

FIG. 3 is a partial cross-sectional assembly view of one embodiment of a rail and panel system through lines 2-2 of FIG. 1, and as shown is configured to be used on a watercraft such as the pontoon boat shown in FIG. 1, the rails are shown in their preassembled configuration;

FIG. 4 is a partial cross-sectional assembly view of the rail and panel system shown in FIG. 3 with the rails shown in their assembled configuration;

FIG. 5 is a partial cross-sectional assembly view of another embodiment of a rail and panel system configured to be used on a watercraft such as the pontoon boat shown in FIG. 1, the rails are shown in their preassembled configuration;

FIG. 6 is a partial cross-sectional assembly view of the rail and panel system shown in FIG. 5 with the rails shown in their assembled configuration;

FIG. 7 is a partial cross-sectional assembly view of another embodiment of a rail and panel system using the rail shown in FIG. 2, the system is configured to be used on a watercraft such as the pontoon boat shown in FIG. 1, the rails are shown in their preassembled configuration; and

FIG. 8 shows a diagrammatical view showing a method of manufacturing the panel and rail system described.

Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplifications set out herein illustrate embodiments of the invention in several forms and such exemplification is not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments discussed below are not intended to be exhaustive or limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings.

A watercraft 10 is shown in FIG. 1, and in this embodiment, watercraft 10 is a pontoon boat. Watercraft 10 includes frame 12, engine 14, pontoons 16, and deck 18. Watercraft 10 also includes a plurality of rails 20 and panels 22 supported by frame 12 and deck 18. Rails 20 are positioned above and below panels 22 to form a boundary around an outer periphery of deck 18 to safely surround passengers on watercraft 10.

A cross-sectional view of a prior art embodiment of upper and lower rails 19 is shown in FIG. 2. Rails 19 secure panels 22 to the watercraft to form an outer boundary of the watercraft. Each rail 19 is constructed of an extruded metallic tube and includes a rail member 17 having a substantially square profile. Rail 19 also includes an extension 15 coupled to one side of rail member 19. This configuration of rail 19 is commonly called a “Q tube.” Extension 15 includes a pair of teeth 21. A receiving area 23 is formed between extension 15 and rail member 17. In FIG. 2, rail 19 is shown in the unassembled orientation. In use, a panel, such as panel 22 in FIG. 1, is positioned in receiving area 23 and extension 15 is bent or crimped toward rail member 17 to secure a panel positioned in receiving area 23 in position. Teeth 21 engage the panel when extension 15 is crimped.

A partial cross-sectional view of another embodiment of upper and lower rails 20 with panel 22 positioned between is shown in FIGS. 3 and 4. Upper and lower rails 20 are identical with respect to form and function and differ only in orientation. Panel 22 is shown in partial for simplicity, and it should be understood that opposite ends are also substantially identical and only differ in orientation.

As shown in FIG. 3, rail 20 includes rail member 24, extension 26, and recessed area 30. In this embodiment, rail 20 is an extruded aluminum tube. In other embodiments (not shown), rail 20 may be constructed of another metallic material, a non-metallic material, or any other suitable material. Rail member 24 has a substantially square profile and a hollow central region. Rail member 24 includes a side 25, from which extension 26 extends. Side 25 and extension 26 form a receiving area 29, for receiving an end of panel 22, as will be described herein. Extension 26 extends from side 25 of rail member 24 and includes an interlocking or engaging portion 28, which is shown as a tab, positioned at one end of extension 26. Recess 30 is formed in side 25 of rail member 24. As shown in FIG. 3, in this embodiment, recess 30 extends about half of the length of side 25.

Panel 22 includes panel member 32 which is continuous between upper end 31 and lower end 33. Upper and lower ends 31 and 33 each include an interlocking or engaging portion 34, which is shown as a tab, that extends substantially perpendicularly from panel member 32. In this embodiment, panel 22 is constructed of polycarbonate. Polycarbonate is dent and scratch resistant and has excellent thermal expansion, toughness, and forming capabilities. Additionally, polycarbonate has heat deflection properties and can be produced in wide variety of colors which may reduce the need for further processing such as painting. Supplemental components such as ultraviolet blockers and stabilizers may be added to polycarbonate to optimize the polycarbonate for the desired application. It should be understood that panel member 22 may be constructed from a polymer based material, a non-metallic material, or any other suitable material.

It should be appreciated that FIG. 3 shows a preassembled position where panel 22 is shown poised for interconnection to rails 20. In this position, upper 31 and lower 33 ends of panel 32 are positioned in corresponding recesses 30, with interlocking portions 34 extending in an overlapping manner with interlocking portions 28.

Referring now to FIG. 4, rails 20 are shown with extensions 26 bent or crimped to secure panel 22 in position between upper and lower rails 20. When extensions 26 are crimped, interlocking portions 28 interlock with interlocking portions 34 to secure panel member 32 in recesses 30. As shown in FIG. 1, rails 19 and panels 22 extend along the length of watercraft 10. In this embodiment, rails 19 have been replaced by rails 20. Assembly of the boundary formed by rails 20 and panels 22 generally includes the steps of positioning a panel 22 between upper and lower rail 20, as shown in FIG. 3, and providing a roller or other crimping device configured to bend extensions 26 from the position shown in FIG. 2 into a position to secure panel 22, as shown in FIG. 4.

With references now to FIGS. 5 and 6, another embodiment will be described. In this embodiment, upper and lower rails 40 are positioned to cooperate with a panel 52. Upper and lower rails 40 include rail members 42, extensions 44, recesses 48, and receiving areas 50. In this embodiment, recess 48 is defined as a notch. Panel 52 includes panel member 54 and interlocking portions 56, which are shown as tabs. Panel 52 is substantially similar to panel 22 with the exception that the orientation relative the rails 40 is reversed, that is interlocking portions 56 are adjacent to rails 40 rather than opposing rails 40. Rails 40 are similar to rails 20 with the exceptions that extensions 44 do not include interlocking portions and recesses 48 are configured to accept interlocking portions 56 of panel 52.

As shown in FIG. 6, extensions 44 are bent or crimped, as described above, toward rail members 42 to contact panel member 54 and secure interlocking portions 56 in recesses 48. Interlocking portions 56 interlock with rail members 42 in recesses 48. Extensions 44, interlocking portions 56, and recesses 48 prevent panel 52 from becoming dislodged if a force is applied to flex panel member 54.

In an alternative embodiment of the rail and panel system shown in FIGS. 3 and 4 and 5 and 6, a rail and panel system including rail 19 of FIG. 2 and non-metallic panel 70 is shown in FIG. 7. Rails 19 and panel 70 are shown in an assembled partial cross-sectional view in FIG. 6. As discussed above, rail 19 includes an extension 15 having teeth 21. Non-metallic panel 70 is substantially flat and includes ends 72 which are configured to be positioned in receiving areas 23 (not shown) of rails 19 during assembly. Extensions 15 are then crimped, which is described below, to secure panel 70 in position. Teeth 21 on extensions 15 contact ends 72 of panel 70 to secure panel 70 between rails 19. In this position non-metallic panel 70 directly contacts rail members 17 and extensions 15.

With reference now to FIG. 8, a method of installing the rail and panel system will be described. The method is shown with the rail and panel system of FIGS. 3 and 4, but the method is equally applicable to the embodiment of FIGS. 5, 6, and 7.

Firstly, with respect to the manufacturing of the rails themselves, the rails 20 may be extruded from a material such as aluminum. The cross section of rails 20 or 40 is conducive to an extrusion process, as all of the configuration is continuous along its entire length. That is, the rail 20 is designed such that all of the features such as rail member 24, extension 26, interlocking portion 28, and recess 30, are continuous along the entire length of the rail, which may make an extrusion process a suitable means for producing rails 20 or 40.

Once the rails are provided, the panel is provided. In one embodiment panels 22, 52 may be formed by a molding or extrusion process. The configuration of panels 22, 52 is also compatible for either process. In either case, the panels are formed to include the interlocking portions 34 at the upper and lower ends 31, 33 of panel 22. It should be appreciated that the panels are formed such that the interlocking portions are spaced apart at the proper distance between extensions 26.

Once the two rails are positioned as shown in FIG. 3, the panel 22 can be slidably received longitudinally into the receiving areas 29, until the panel 22 is fully installed. At that point, a crimping roller, such as 60, which is rotatable about axis A-A, can be used to crimp extensions 26 into place. For example, roller 60 can begin at one end of rail 20 and move longitudinally along the length of rail 20 to roll the extensions from the position of 26-1 to the position of 26-2, where interlocking portions 28 overlap and interlock with interlocking portions 34.

While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains. 

1. A watercraft including: a frame; a rail supported by the frame; and a non-metallic panel supported by the rail.
 2. The watercraft of claim 1, wherein the non-metallic panel is constructed of a polymer based material.
 3. The watercraft of claim 1, wherein the non-metallic panel is constructed of polycarbonate.
 4. The watercraft of claim 1, wherein the watercraft is a pontoon boat.
 5. The watercraft of claim 1, wherein the rail and the non-metallic panel cooperate to define a boundary of the watercraft.
 6. The watercraft of claim 1, wherein the rail is formed from a substantially square shaped tube.
 7. The watercraft of claim 1, wherein the non-metallic panel has interlocking portions adjacent to a top and bottom edge, that are profiled to interlock with the rail.
 8. The watercraft of claim 7, wherein the tube includes four sides and an extension coupled to one of the sides.
 9. The watercraft of claim 8, wherein the tube includes a recess adjacent to the extension.
 10. The watercraft of claim 9, wherein the extension includes a first tab co-operable with said interlocking portions.
 11. The watercraft of claim 10, wherein the non-metallic panel includes a second tab configured to cooperate with the recess and the first tab to couple the panel to the tube.
 12. The watercraft of claim 9, wherein the recess is defined as a notch and the non-metallic panel includes a second tab configured to be positioned in the notch.
 13. The watercraft of claim 7, wherein the non-metallic panel is configured to directly contact both the extension and the one of the tube including the extension.
 14. The watercraft of claim 1, wherein the non-metallic panel includes a panel member that defines a first plane and a tab extending from the panel member substantially perpendicularly relative to the first plane.
 15. The watercraft of claim 1, wherein the non-metallic panel is configured to couple directly to the rail.
 16. A watercraft including: a frame; a rail member supported by the frame; a panel member coupled to the rail; and means for coupling the panel member to the rail member.
 17. The watercraft of claim 16, wherein the panel member is constructed of a polymer based material.
 18. The watercraft of claim 16, wherein the means for coupling the panel member to the rail member includes a tab positioned on the panel member.
 19. The watercraft of claim 16, wherein the means for coupling the panel member to the rail member includes a recessed portion in the rail member.
 20. The watercraft of claim 16, wherein the means for coupling the panel member to the rail member includes an extension coupled to the rail member.
 21. A boundary for a watercraft, the boundary comprising: a rail including a recessed portion and an extension; and a panel including first and second ends, the first end including an interlocking portion.
 22. The boundary of claim 21, wherein the interlocking portion of the panel is configured to be positioned in the recessed portion of the rail to couple the panel to the rail.
 23. The boundary of claim 22, wherein the extension is configured to bend to contact the interlocking portion of the panel to couple the panel to the rail.
 24. The boundary of claim 21, wherein the extension includes a tab configured to correspond to the engaging portion of the panel to couple the panel to the rail.
 25. The boundary of claim 21, wherein the panel is constructed of a polycarbonate material.
 26. The boundary of claim 21, wherein the rail includes four sides and one of the sides includes both the recessed portion and the extension.
 27. The boundary of claim 21, wherein the first and second ends of the panel define a first plane and the interlocking portion is substantially perpendicular to the first plane.
 28. A method of manufacturing a watercraft, comprising the steps of: providing a flotation platform; extruding a plurality of rails; defining a rail structure by attaching the plurality of rails to the flotation platform; providing a polymer based panel; and interlocking the polymer based panel to the rails to define a boundary wall.
 29. The method of claim 28, wherein the flotation platform is defined as a pontoon boat platform.
 30. The method of claim 28, wherein the flotation platform defines a periphery and the rail structure is supported by the flotation platform around the periphery.
 31. The method of claim 28, wherein the rails are extruded to define a generally Q-shape.
 32. The method of claim 31, wherein the Q-shaped rails are extruded to define a generally square cross section with an extending portion.
 33. The method of claim 31, wherein the polymer based panel and the rails are interlocked to each other by providing an interlocking tab on the panel adjacent to an edge of the polymer based panel
 34. The method of claim 33, wherein the polymer based panel is positioned in a receiving area between the square cross section and the extending portion, and the extending portion is crimped to form the interlocking engagement.
 35. The method of claim 33, wherein two Q-shaped rails are provided in parallel with the receiving areas positioned in a facing relationship, and the polymer based panel is positioned between the parallel rails in the receiving areas.
 36. The method of claim 34, wherein the extending portion of the Q-shaped rails has a complementary overlapping tab and the overlapping tabs on the panel and the Q-shaped rails interlock the panel and rails together.
 37. The method of claim 34, wherein the Q-shaped rails are extruded to define a notch in the square portion and opposed to the extending portion, whereby the interlocking tab of the polymer based panel is received in the notch, and the extending portion is subsequently crimped to entrap the panel.
 38. A boundary for a watercraft, the boundary comprising: a rail including a recessed portion and an extension; a panel configured to be attached to the rail; and cooperative interlocking members associated with the panel and the rail, the members configured to attach the panel to the rail.
 39. The boundary of claim 38, wherein the cooperative interlocking members include a first tab positioned on the extension and a second corresponding tab positioned on the panel.
 40. The boundary of claim 38, wherein the first tab is configured to interlock with the second tab to couple the panel to the rail.
 41. The boundary of claim 38, wherein the panel is constructed of a polycarbonate material.
 42. A method of making a rail for a watercraft, and for use with a panel having tabs along an edge thereof, the method including the steps of: providing a metallic material; and extruding the metallic material to produce a tube having a substantially square cross section including an extension and a recess, the recess adjacent to the extension.
 43. The method of claim 42, wherein the extension is provided with a tab for interlocking with the panel tab.
 44. The method of claim 42, wherein the recess is provided as a notch for receiving the panel tab.
 45. A pontoon boat including: a flotation platform defining a perimeter; a motor supported by the flotation platform; a plurality of rails supported by the flotation platform, the rails positioned around the perimeter, the rails including a substantially square tube having a recess and an extension positioned adjacent the recess, the extension including a first tab; and a plurality of polymer based panels having first and second ends and sides extending therebetween, each of the panels including a second tab on each side, the second tab configured to interlock with the first tab of the extension to secure the panels to the rail.
 46. A method of manufacturing a watercraft, comprising the steps of: providing a flotation platform; extruding a plurality of rails; defining a rail structure by attaching the plurality of rails to the flotation platform; providing a non-metallic panel; and coupling the non-metallic based panel directly to the rails to define a boundary wall.
 47. The method of claim 46, wherein the rails are extruded to define a generally Q-shape.
 48. The method of claim 47, wherein the Q-shaped rails are extruded to define a generally square cross section with an extending portion.
 49. The method of claim 48, wherein the non-metallic panel is positioned in a receiving area between the square cross section and the extending portion, and the extending portion is crimped to contact the non-metallic panel. 